Allen, I've lost my crackle.....

[Hellbender]

Allen, I have an ESAB Migmaster 250 (bought it used) and a few weeks ago it lost it's "crackle" sound when you weld.

It's not adjustments or out of gas, it still welds (I can even lay a nice bead), but the wire seems to kinda "worm" it's way into the puddle and most obviously the "crackle" sound is gone, no matter the adjustment, wire speed or heat.

Have you ever ran into anything like this?

Thanks for any suggestions,

HB

[mrblaine]

It appears you burnt out your current crackle module.

You need to go to the ESAB site and request the part # and installation instructions their new crackle module. It is programmable and will provide any sound you want up to and including the correct "crackle".

[Krash80]

Interesting...my welder just CACKLES at me when i try to use it.

[JEEP_TJ_FREAK]

Same OD wire as last week or did you buy a new spool?

[Allen]

Nice welder. I've used ESABs quite a bit.

When your welding, does the wire come out of the guide tube and "pig tail" into the puddle? Making it difficult, but not impossible, to keep the wire in the root and make a straight weld?

And it doesn't do in constantly, but intermittently?

Did you just buy a new spool of wire recently? More on that in a minute.

The cheapest thing you can do that "may" be the problem is to first look at your drive roller tension. Try increasing it. Make sure you're using the right roller groove for the diameter wire you're using.

If that doesn't do it, replace the drive rollers.

If that doesn't do it, if you have an extra whip lying around try that. Highly doubtful it's the whip, but I've seen it a time or two.

Lastly, replace the spool of wire. Sometimes when they wind them at the weld wire factory, they do it incorrectly. I've seen anywhere form 60lb coils wound wrong all the way up to 2000lb coils. Lincoln gets a little testy when you defect out a 2000lb coil of wire. Or several.....

Lemme know.

Allen

[Hellbender]

So much for all the wise "crackles", a real bunch of buddies here

No changes, same roll of wire.

Allen, yes, it pigtails out (the worm effect I spoke of), but does it all the time.

I'll clean and adjust the rollers and play w/ them some and I have a spare whip, I'll try those things.

I was trying to blame it on the arc frequency (or some other nebulus thing I don't understand) and never thought of the simple mechanics (wire feed).

It may be a day or 2, but I'll let you know.

Thanks,
HB

[Allen]

All the time?

Like on every roll of wire you've run?

I've never seen that.

Doesn't much sound like a bad spool if that's the case.

Allen

[Hellbender]

Allen, this is the ONLY spool of wire I've ever had w/ this welder, it was a new spool and it's about 1/2 gone, now.

I also remembered something I added that may have caused the trouble (now that I know where to look)....

The little felt thing that lubes the wire before it goes into the rollers was off and I got some of the proper lube and put it back on..................duh, it's slipperier, now

Thanks for the help.
HB